Method for making an abrasive article and abrasive articles thereof

A method for making an abrasive article comprising:

• filling a plurality of bristle segments of an abrasive article mold with abrasive particles, such that the bristle segments are filled to a level of at least 50% by volume;
• supplying a binder precursor matrix comprising at least two interactive components to the abrasive article mold, wherein a first component is selected from the group consisting of a polyurea or polyurethane/urea which results from the polymerization of a polyfunctional amine having functionality of at least 2 and an equivalent weight of at least about 300 and a polyfunctional isocyanate prepolymer having functionality of at least 2 and an equivalent weight of at least about 300;
• and a second component is selected from the group consisting of a polymerized polyfunctional isocyanate or polyfunctional amine having a functionality of at least about 2 and equivalent weight of less than about 300;
• and
• allowing the binder precursor matrix to cure within the abrasive article mold such that the abrasive particles are secured within a binder formed from the binder precursor matrix, wherein the binder includes a soft segment to hard segment ratio of about 10:1 to about 0.5:1.

A method for making an abrasive article comprising:

• dry filling a plurality of bristle segments of an abrasive article mold with abrasive particles, such that the bristle segments are filled to a level of at least 50% by volume;
• supplying a binder precursor matrix comprising at least two interactive components to the abrasive article mold, wherein a first component comprises a glycidyl ether monomer of the formula:
• where R1 is alkyl or aryl and m is an integer of 1 to 6;
• and a second component comprising a polyether diamine having an average molecular weight from about 175 to about 750 of the formula
• H2N—R2O[Parenopenst]R3O[Parenclosest]nR2—NH2
• wherein R2 is a linear or branched chain alkylene group having 2 to 4 carbon atoms, R3 is an hydrocarbolene group having 2 to 8 carbon atoms selected from straight and branched chain alkylene groups having 2 to 4 carbon atoms, cycloalkylene groups having 4 to 8 carbon atoms, and arene groups having 6 to 8 carbon atoms, and n is a number from 1 to 10;
• and
• allowing the binder precursor matrix to cure within the abrasive article mold such that the abrasive particles are secured within a binder formed from the binder precursor matrix, wherein the binder and the plurality of abrasive particles are in a ratio of about 1:3 or more by weight.

An integrally molded abrasive article comprising:

• a base having a first side and a second side;
• a plurality of bristles integrally molded with and extending from the first side of the base;
• wherein the base comprises a binder formed from a binder precursor matrix substantially free of abrasive particles comprising a first component selected from the group consisting of an amine, a polyol, or a mixture thereof, wherein the first component has an average amine or hydroxy functionality of at least about 2 and an equivalent weight of at least about 30 grams and less than about 10,000 grams per equivalent;
• and a second component comprising a polyfunctional isocyanate having an average isocyanate functionality of at least 2 and an equivalent weight of at least about 80 grams and less than about 5000 grams per equivalent;
• and at least a portion of the plurality of bristles comprise a plurality of abrasive particles adhered within the binder such that the ratio of binder to abrasive particles is at least about 1:3 by weight.